Solar Panel Flashing Mount With Adjustable Seal Compression
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Solution Overview
Problem
Conventional flashing devices for solar panels often lack adequate pressure on seals, do not allow for adjustable mounting, are costly, and fail to optimize material usage, particularly when dealing with rail-free systems and misalignment during installation.
Innovation Solution
An attachment system for solar equipment featuring a support portion with a fluid restrictor and a flashing plate, including a variably positionable bracket and fastener that adjusts compression on the fluid restrictor, providing improved sealing and adjustability, and optimized material usage through geometric designs like the cardioid shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flashing devices are used, then the structure is simple and easy to manufacture, but they do not provide adequate pressure on the seal around the lag screw
Solution Approach 1:
The patent applies the dynamics principle by making the support portion rotatable relative to the flashing plate. This rotation allows the installer to adjust the compression force on the seal dynamically during installation, ensuring adequate sealing pressure without requiring an overly complex device structure. The rotatable joint transforms a static connection into a dynamic adjustment mechanism.
Solution Approach 2:
The patent changes the compression parameter of the seal by allowing rotation of the support portion. This rotational movement directly alters the compressive force applied to the seal around the lag screw, enabling the system to achieve reliable sealing by adjusting this critical parameter without fundamentally redesigning the entire device.
2Adaptability or versatility
If conventional flashing devices are used, then the manufacturing cost is lower, but they do not allow for a separately positionable bracket that enables adjustability relative to the lag screw after installation
Solution Approach 1:
The patent segments the device into separable components: the flashing plate, the support portion, and the bracket. This segmentation allows the bracket to be positioned separately and adjusted relative to the lag screw after installation, providing the required adaptability while keeping each individual component relatively simple in structure.
Solution Approach 2:
The patent implements dynamics by enabling the bracket to be repositioned and adjusted after the initial installation. The rotatable support portion and separable bracket create a dynamic system that can adapt to different mounting requirements without requiring a completely new device design.
3Loss of substance
If conventional flashing devices are used, then the material usage is straightforward, but they are costly and do not optimize materials usage
Solution Approach 1:
The patent employs a cardioid shape for the support portion, which is a curved geometric form. This curved design optimizes material distribution and structural efficiency, allowing the device to achieve required strength and sealing with more efficient material usage compared to conventional straight-edged designs, while remaining manufacturable.
Solution Approach 2:
The patent utilizes composite construction by combining different materials for different functions: the flashing plate (typically metal) for structural support and weather resistance, the seal (elastomeric material) for waterproofing, and the support portion for mechanical connection. This composite approach optimizes material usage by selecting the right material for each specific function.
4Reliability
If conventional flashing devices are used, then the installation process is simple, but they do not properly account for misalignment of components during installation
Solution Approach 1:
The patent applies dynamics by allowing the support portion to rotate relative to the flashing plate during installation. This rotational freedom provides tolerance for misalignment between components, enabling the installer to accommodate slight positioning errors without requiring precise alignment, thereby improving installation reliability while adding minimal operational complexity.
Solution Approach 2:
The cardioid shape of the support portion is an asymmetric geometry that provides functional advantages for alignment tolerance. The asymmetric form allows for easier insertion and accommodation of misalignment in one direction while maintaining secure connection, addressing the misalignment issue inherent in symmetric conventional designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances sealing efficiency, allows for flexible mounting adjustments, reduces material costs, and effectively addresses misalignment issues, improving the overall installation process for solar panels on various surfaces.
Implementation Method 1
rotation or advancement of the fastener varies an amount of compression on the fluid restrictor portion
Data Source
AI summary
A method, system and apparatus are disclosed regarding an attachment system for solar equipment, sometimes referred to as a flashing device allowing quick and easy assembling of the solar equipment into an array or other combination in a sturdy and durable manner. In examples of the present technology, a flashing device may include a flashing plate which may contain one or more raised features to further direct and control the flow of liquid over the flashing plate. The flashing device may also contain a fluid restrictor such as a seal or part of a seal usually held within an aperture of a block having a skyward facing essentially or substantially flat surface. One or more various items of solar equipment may be attached to the essentially flat surface of the block. Also disclosed are adjustable mounting feet which may be installed in connection with other solar equipment.